Construction material



unrrsov STATES RAY. P. PERRY, OF

PATENT oFFicE.

ASSIGNOR TO THE BARRETT CON STRUCTION MATERIAL.

No Drawing.

T 0 a? Z whom it may con cam.

Be it known that I, RAY P. PERRY, a citizen of the United States, residing at Upper Montclair, in the county of Essex and State of New Jersey, have invented certain new and useful Improvements in Construction Materials, of which the following is a specification.

This invention relates to a construction material and the process of producing the same. It relates more particularly to a construction material containing fibrous material and water proofing material, such for example as pitch, asphalt, and the like.

Heretofore it has been well known that sheets of material suitable for roofing, wall boards, etc., can be formed on an ordinary paper making machine. It is also well known that during the paper making process comminuted water proofing material may be introduced into the pulp in the paper making machine and becomes incorporated in the sheet as the sheet is formed. sheets the water proofing material may be subsequently fused and caused to spread uniformly by heating or by heating, and pressing the same. It has been observed that in the making of such sheets on a paper making machine the fibers arrange themselves in large measure in directionsparallel with the longitudinal dimension of the sheet. The fibers may be'interlaced or felted together and cross each other to some extent but a large proportion iies in a direction longitudinal of the sheet.

In my prior application Ser. No. 398,229, filed July 22, 1920, is described a process by which sheets or layers of mixed fibers and comminuted water proof ing material are superposed upon each other and intimately united by heat and pressure.

The present invention is an improvement over the prior art in that the construction material made in accordance with this invention possesses properties not present in the articles heretofore made. One of the main advantages of the present invention is that the article produced has less tendency to be split or fractured and is also less apt to sag after being installed. I take sheets or layers of mixed fibers and Water proofing materials that have been formed on a paper making machine and ply the same together so that the fibers in one sheet or layer lie at an angle to the fibers in an adjacent sheet or layer and then intimately unite thesheets by Specification of Letters Patent.

In such sheet as it comes from the paper making Inachine is at right angles to the longitudinal edge of the next sheet, but certain advantages may be obtained by turning the sheets with respect to each other at an angle less than a right angle.

It will be obvious that the pieces or layers cut from the sheet formed on the paper making machine may assume a great variety of shapes such as square, triangular, rectangular, trapezoidal, etc. In every case the pieces or plies will be so assembled that the general direction of the fibers in one piece or ply is at an angle to the general direction of the fibers in the adjacent piece or ply. In case of pieces of certain shapes such as rectangular or otherwise the ends or corners of an" overlying sheet will project beyond the edge of the next sheet so thatwhen heat and pressure are applied to produce unification the overhanging portions. may not be compressed or densified. As a result of the hot pressing operation the contacting parts become intimately united and form a substantially homogeneous and integral article.

The invention will be more particularly illustrated by the following specific example which is not intended to restrict the invention to the particular materials mentioned. About 20 to 35% of paper making stock such as rag stock, wood fibers, etc., may be mixed with about 80 to 65% minuted Waterproofing material such as pitch of a melting point of 280 F.-to 300 F. more or less and formed into -a sheet on the paper making machine. A substantial portion of the water may be removed from the sheet, or the sheet may be partially or entirely dried sired shape, which strips are assembled so that the general direction of fibers in one strip lie at an angle, preferably a right angle, to the general direction of fibers in the next strip. The group of assembled or laminated strips is then pressed in the presence of sufiicient heat to fuse the pitch at such a pressure, say 150 to 300 pounds more or less per square inch, so that the thickness may be reduced to about one-half of the original thickness. The pressure should preferably be applied perpendicular to the sheets so that they will not become torn during the press- Patented Dec. 13, 1921. Application filed September 3, 1920. Serial No. 407,989.

by weight of com-' substantially orentirely obliterated, thus forming an integral homogeneous article. If necessary the strips ma be cooled while the pressure is still applie in order for the waterproofing material to set so that the article will not. expand after the pressure is removed. I

It has been found that an article produced in accordance with this invention will withstand fracture or splitting in a very effective manner and that the tendency for it to sag or, bend even when installed on a roof in hot climates or in locations where unusually high atmospheric temperatures are reached is overcome. The degree of hardness and rigidity of the product will depend in large measure upon the proportion of waterproofing material and the melting point of the same. The articles made hereby are found to be substantially impervious to water.

I claim- 1. The process which comprises forming sheets containing fibrous material and water proofing material-so that the fibers lie in one general direction, plying a plurality of such sheets together so that fibers in one sheet are at an angle to those in an adjacent sheet, and heating and pressing the same.

2. The process which comprises forming sheets containing fibrous material and waterproofing material on a paper making machine so that the fibers lie in one general direction," plying a plurality of such sheets together so that fibers in one sheet are at an angle to those in an adjacent sheet, and heating and pressing the same.

3. The process which comprises forming sheets containing fibrous material and waterproofing material so that the fibers lie in one general direction, plying a plurality of such sheets together so that fibers in one sheet cross those in an adjacent sheet, and heating and pressing the same.'

'4. The process which comprises forming sheets containing fibrous material and waterproofing material so that the fibers lie in one general direction, plyin a plurality or such sheets together so that bers in one sheet are at an angle to those in an adjacent sheet, and uniting said sheets by heat and pressure.

. 5. The process which comprises forming sheets containing fibrous material and pitch a so that the fibers lie in one general direction,

plying a plurality of such sheets together so that fibers in one sheet are at an angle to those in an adjacent sheet, and heating and pressing the same.

6. The herein described rocess which comprises uniting sheets of fi rous material and waterproofing material by heat and presproximately sure, thefibrous material in the individual sheets being somewhat alined and the fibers in one sheet being at an angle to those in an adjacent sheet.

7. The herein described process which comprises uniting sheets of fibrous material and pitch by heat and pressure, the fibrous material in the individual sheets being somewhat alined and the fibers in one sheet being at an angle to those in an adjacent sheet.

8. As an article of manufacture, a construction material comprising sheets of mixed fibrous and waterproofing materials which have been united by heat and pressure, the fibers in the sheets being substantially alined and those in one sheet being at an angle to those in an adjacent sheet.

9. As an article of manufacture, a construction material comprising sheets of mixed fibrous and waterproofing materials which have been united by heat and pressure, the fibers in the sheets being substantially alined and those in one sheet being at substantially right angles to those in an adjacent sheet. a

10. As. an article of manufacture, a construction material comprising sheets of mixed fibrous material and pitch which have been united by heat and pressure, the fibers in the sheets being substantially alined and those in one sheet being at an angle to those in an adjacent sheet.

11. As an article of manufacture, a -construction material comprising sheets of mixed fibrous and waterproofing materials which. have been united by heat and pressure and densified to substantially one-half their original thickness, the fibers in the sheets being substantially alined and those in one sheet being at an angle to those in an ad a cent sheet.

.12. As an article of manufacture, a construction material comprisingsheets of mixed fibrous and waterproofing materials in apthe proportions of 1 to 4 by weight which have been united by heat and pressure, the fibers in the sheets being substantially alined and those in one sheet being at an angle to those in an adjacent sheet.

13. As an article of manufacture, a construction materialcomprising sheets ofmixed fibrous material and pitch of a melting point of approximately 300 F. which have been united by heat and pressure, the

fibers in the sheets being substantially alined 

